Phenix 635-5P User manual

PORTABLE AC DIELECTRIC TEST SET

Model Number 635-5P

LO/ch

October 17, 1997 +

TABLE OF CONTENTS

Section Number

DANGER

TECHNICAL SPECIFICATIONS 1

INTRODUCTION 2

SAFETY 3

CONTROLS AND INSTRUMENTATION / FIGURE 1 4

SET-UP AND OPERATION 5

ELECTRICAL SCHEMATICS 6

PARTS LIST 7

MAINTENANCE 8

WARRANTY 9

RETURNED MATERIAL 10

PARTS ORDERING INFORMATION 11

RECOMMENDED SPARE PARTS 12

1-1

TECHNICAL SPECIFICATIONS

INPUT: 120 VAC, 2 A, 1 phase, 60 Hz

OUTPUT: 0-35,000 VAC

Due to the short circuit current limiting of the 635-5P, the following maximum full

output voltages are available at the specified currents.

Output Current Approx. Max. Voltage Available

1 mA 32 kV

2 mA 27 kV

3 mA 24 kV

4 mA 20 kV

5 mA 15 kV

6 mA 10 kV

Current limited to <10 mA output on short circuit.

INSTRUMENTATION:

Voltmeter: 3 1/2 digit LCD display

Scale: 0-35.0 kVAC

Accuracy: +/-1% FS

Currentmeter: 3 1/2 digit LCD display

Scale: 0-10.0 mA AC

Accuracy: +/-1% FS

DIMENSIONS: 18.5" H x 13.5" W x 11" D; 66 lbs.

(470 mm H x 343 mm W x 279 mm D; 30 kg)

2-1

INTRODUCTION

The Phenix Model 635-5P is a portable AC Dielectric Test Set for performing dielectric strength

tests primarily on vacuum bottles. The test set may also be used for testing other samples which

are no load or light load (< 1 mA) in nature. A built-in self-protection feature current limits the

short circuit output current to safe levels, preventing damage to the test set. Under dead short

conditions, the output voltage will drop to zero.

3-1

SAFETY

Because the 635-5P is designed to supply high voltages, safeguards have been built into it.

These safeguards are only effective if safe work practices are also used. The test set and these

procedures have been designed for use by knowledgeable electrical workers who have been

properly trained in its use.

Please note the following:

1. The test set must be grounded. The third prong on the input power plug is for this purpose.

DO NOT REMOVE THIS PRONG.

2. The tests described here are to be used ONLY on DE-ENERGIZED and isolated

transformers.

3. HIGH VOLTAGES (LETHAL IN VALUE) ARE GENERATED DURING THE TESTS AND

EXTREME CAUTION MUST BE USED. FOLLOW ALL SAFETY PROCEDURES.

GROUND OBJECT UNDER TEST BEFORE TOUCHING.

4. High Voltage section is located in a plastic case. DO NOT touch case while high voltage is

energized. Do not touch high voltage output lead when high voltage is energized.

5. Maintain safe working distances when the test set is energized.

4-1

CONTROLS AND INSTRUMENTATION

The following is a brief description of the various controls and instrumentation found on the Model

635-5P.

Refer to Figure 1.

1. Main Power On Switch. Toggle switch supplies power to test set.

2. ON Indicator Lamp. Neon lamp indicates Main Power is ON.

3. Fuse. Overload protection for all control, metering, and power circuits.

4. High Voltage ON. "Deadman" pushbutton must be depressed and held to energize high

voltage. Pushbutton will light when high voltage is energized. Failure to hold down

pushbutton will cause high voltage to de-energize. Pushbutton is zero start interlocked.

5. Fault Indicator Lamp. Neon indicator lamp will glow or flicker indicating breakdown or

arcing within the object under test.

6. Voltage Adjust Knob. Controls output voltage from zero to full output voltage. Knob

must be in the zero or full counter clockwise position to energize high voltage.

7. Output Kilovoltmeter. Digital LCD display indicates output voltage. Scale: 0-35.0 KVAC.

8. Output Currentmeter. Digital LCD display indicates output current. Scale: 0-10.0 mAAC.

5-1

SET-UP AND OPERATION

1. Place unit on bench or other suitable flat surface.

2. Undo (2) latches on side of case.

3. Remove cover, power, control, return, and output cables. Exercise caution in removing cover

because control cables are permanently connected to the bottom of the case.

4. Separate High Voltage (bottom) section and control (cover) section to provide safe operating

distance between operator and high voltage.

5. Locate red high voltage output lead. Insert banana jack end of lead into jack provided on top

of high voltage section.

6. Connect high voltage and low voltage return leads to object under test.

7. Connect input power cord to a 117 VAC, 60 Hz grounded outlet.

8. Turn on Main Power toggle switch. Main Power indicator lamp should glow. Digital output

meters should now display zeros (+/-1 count).

9. Turn output voltage control knob to zero (full counter clockwise position). Depress high

voltage on pushbutton. Button should now glow indicating high voltage is energized. Raise

output voltage to desired test level by turning voltage control knob clockwise.

While raising the output voltage, pay special attention to the output currentmeter. If it should

suddenly show a high reading, this means the sample has broken down. Arcing or temporary

breakdowns will be indicated by the fault lamp.

10. At completion of high voltage test, return voltage control knob to zero and release high voltage

on pushbutton. High voltage on lamp should go out. If high voltage on pushbutton is released

while voltage control knob is off of zero, high voltage will deenergize and cannot be renergized

until voltage control knob is returned to zero.

11. To repack unit for transport, reverse step 3 above. Be sure to remove high voltage lead from

jack on top of high voltage section. Failure to do so may scratch or damage control panel.

A Note About Automatic Current Limit Circuit:

Unit is equipped with automatic current limit circuit which limits maximum output current to

approximately 10 milliamperes under dead short conditions. This feature consists of a high

impedance high voltage transformer combined with a series connected primary resistance to limit

the maximum current. This circuit will allow you to attain maximum output voltage when unit is

lightly loaded (less than 1 milliampere) while protecting the unit from damage when shorts or

breakdowns occur in the object under test.

6-1

ELECTRICAL SCHEMATICS

Drawing Number Description

1. -01-E634 Model 635-5P Portable AC Dielectric

2. -01-P118 Dual 5 VDC Power Supply PC Board

3. -01-P119 Meter Calibration PC Board

7-1

PARTS LIST

ITEM DESCRIPTION PART NO.

A1 PCB1165 Dual 5VDC Power Supply 31116500

A2 PCB1166 Meter Cal Board 31116600

BDG1 Diode Bridge 1789210

C1 Capacitor, .22µfd, 400V 1093170

C2 Capacitor, .01µf, 1kV 1092050

F1 Fuse, 5A, 250V, 3AG 1603605

Relay Socket, 3 Pole 1157620

J1 Corcom Connector 1152590

J2 10 Pin Female Recept. 1150128

J2 10 Pin Male Plug 1150129

Clamp 1150926

K1 Relay, 3PDT, 115VAC 1700610

M1-2 Meter, Acculex DP652 1506400

PL1,3 Lamp, Neon 115VAC 1423260

R1 Resistor, 2.7K Ohm, 2W 1712085

R2, A&B Resistor, 50 Ohm, 200W 1740208

Resistor, 500 Ohm, 50W 1741030

R3 Resistor, 10 Ohm, 2W 1710155

R4-2pcs. Resistor, 75M Ohm, 6W 1748200

R5 Resistor, 2K Ohm, 1/2W 1722078

R6 Resistor, 5K, 1/2W 1712110

R7 Resistor, 1.2M Ohm, 1/2W 1715996

S1 Switch, Toggle, DPDT 1865005

S2, PL2 Switch, Pushbutton, EAO 1860120

Lamp, 60V 1420150

Lens, Red 1422150

SCR1 SCR, C106D 1803100

SG1 Spark Gap, 90V 1605110

T1 Variac, Staco 221 1890105

T2 Transformer, HV, Phenix GV1118 38321118

Z1,2 5.6V Zener 1780034

Miscellaneous Components

Line Cord, 18/3, 8 ft. long 1077167

Case, Anvil 16”H x 9 ½”Dx 12”W 2100525

Return Lead, #10AWG, Hypalon 1078170

Clip #27C 1353042

Boot, Black 1353041

High Voltage Lead --

Clip #27C 1353042

Boot, Red #29 1353040

Plug, Banana, Red 1356200

Interconnect Cable, 4 Cond, 20AWG (2 pcs.) 1075040

8-1

MAINTENANCE

No solution or chemical stronger than ordinary mild soap and water solution should be applied to

the cabinet area of this unit. Care must be used when cleaning the meter faces and console

panel. Abrasives may remove printing and descriptive titles and scratch meter faces. When

cleaning, always have unit disconnected from power source. Never attempt to clean inside the

unit as the cleaning solution may cause damage to the electronic components.

In the event it becomes necessary to replace any parts, a complete description can be found with

the supplied parts list.

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